Reusable Packaging Engineered for a Circular Delivery Model
Olive is a consolidated e-commerce delivery service built to reduce last-mile waste. Orders from multiple fashion retailers are grouped into a single weekly delivery, sent in reusable packaging, and returned on the next cycle. No cardboard. No plastic mailers.
Kargo designed and engineered a line of collapsible, reusable totes made from 100% recycled materials, then managed production and supply chain integration. The packaging had to perform across fulfillment, transit, customer use, and return
The Challenge
Olive's requirements left little room for compromise. The system needed 100% recycled materials, durability across multiple use cycles, product protection without extra padding, and structural integrity through fulfillment handling.
It also had to optimize dimensional weight pricing. A bulky tote would raise shipping costs at scale and undermine the entire service model.
Returns were equally critical. Customers had to flatten each tote quickly for the next pickup. If the construction felt awkward or bulky, the reverse logistics model would break.
Design & Engineering
This project was as much an engineering problem as a packaging brief. Structure, materials, and brand presentation had to work as one system.
Exterior and interior fabric: 100% recycled RPET for durability and lightweight performance
Zipper coil and tape: 100% recycled RPET
Structural layer: 100% recycled corrugated PP board for rigidity without cardboard
Fabric treatment: DuPont antibacterial coating on both sides for hygiene across reuse cycles
Closure: tamper-evident seal for transit security
Collapse ratio: totes flatten to 10% of expanded volume in seconds
Multiple sizes developed for different order volumes
The structure holds shape in transit, protects mixed fashion orders without dunnage, and collapses flat for return. Branding was built into the construction rather than added as extra materials.
The Solution
Kargo managed the full scope: material research, structural engineering, prototyping, branding integration, production, and supply chain coordination.
We developed the materials and constructions from scratch rather than selecting from existing tote stock. Production was managed through to delivery so the system could be used consistently across Olive's fulfillment network.
Results
Lower shipping costs through right-sized structures and a high collapse ratio
Single-use packaging removed from the delivery cycle
100% recycled construction across every component
Faster, simpler customer returns
Packaging that held up across multiple shipping cycles
Services Used:
Design & Engineering
Product Development
Production
Logistics
Supply Chain Management
